Highly filled polymeric concentrates

ABSTRACT

A composition comprises a highly filled polymeric concentrate produced by melt processing a filler with a liquid polymeric dispersion.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of application Ser. No. 15/571,454filed Nov. 2, 2017, which is a National Phase entry of PCT ApplicationNo. PCT/US2017/019420, filed Feb. 24, 2017, which claims the benefit ofU.S. Provisional Application No. 62/299,858, filed Feb. 25, 2016 andU.S. Provisional Application No. 62/346,154, filed Jun. 6, 2016, each ofwhich is hereby fully incorporated herein by reference.

TECHNICAL FIELD

This disclosure relates to compositions and methods for producing highlyfilled polymeric concentrates.

BACKGROUND

There is a need in the market for highly filled polymeric concentratesor masterbatches. Today, depending on the type and attributes (e.g.,specific gravity, surface area) of the filler, it is difficult toproduce polymeric concentrates at levels greater than about 80 weight %or 50 volume % filler using conventional melt processing techniques.Around and above these loading levels the viscosity of the polymericconcentrate becomes too high and can ultimately torque out (viz., stall)the processing equipment. It is also difficult to maintain consistencyin the final product when feeding fillers at such loading levels,especially in low bulk density materials. Lastly, the break up anddispersion of additives in the polymeric concentrates becomes morepronounced as the loading level of fillers increases, which can lead topoor performance in the end product.

SUMMARY

We have discovered that, by utilizing liquid polymeric dispersions, wecan produce polymeric concentrates at levels greater than 80 wt % or 50volume % using melt processing techniques. In one non-limitingembodiment, for example, a polymeric concentrate can be made using highspeed mixing of an additive with a waterborne polymeric dispersionfollowed by pelletization using a California pellet mill and/ortwin-screw extrusion. The polymeric concentrates described in thisdisclosure provide significant value to plastics compounders andconverters. These polymeric concentrates are easier to handle, more costeffective and more easily dispersed than competitive materials currentlyon the market.

In one embodiment, a filler is melt processed with a liquid polymericdispersion, which includes, e.g., a polymer dispersed or dissolved in aliquid carrier. In another embodiment, the liquid dispersion is awaterborne polymeric dispersion. In a preferred embodiment, thewaterborne polymeric dispersion is a waterborne polyolefin dispersion.In one embodiment, filler level in the final polymeric concentrate aftermelt processing is greater than 80 wt % or 50 volume %. In preferredembodiments, the filler level in the final concentrate is greater than90 wt % or 60 volume %. The polymeric concentrates of this disclosurecan be convened into articles using melt processing techniques, such ascompounding, extrusion, and molding. Such articles have utility in avariety of markets including automotive, building and construction,consumer and appliance markets.

Using a liquid polymeric dispersion provides a number of advantages. Forexample, using a liquid polymeric dispersion can lower the overallviscosity of the highly filled polymeric concentrate making it easier tomelt process. The liquid polymeric dispersion also effectively andefficiently coats the filler, such that upon removal of the liquidcarrier, the polymer remains uniformly coated onto the additive surface.Due to the uniformity of the polymer coating, upon let-down, the polymerbegins to flow and causes the additive to disperse, leading to enhancedphysical properties in the end product. Finally, the liquid carrier candensify the additive making it possible to achieve higher loadings inthe final polymer concentrate.

Using the disclosed liquid polymeric dispersion provides an unexpectedway of making highly filled polymeric concentrates. Typically, thepresence of liquids (e.g., moisture or solvent) can cause severe issuesfor melt-extrusion, such as hydrolysis of the polymer or degradation offillers. Furthermore, because the liquid polymeric dispersion can have ahigh liquid content greater than 50 wt %, it normally would be difficultto control and efficiently melt process the dispersion. With appropriateprocessing, however, liquid dispersion can be used to prepare low-cost,highly filled, and well-dispersed polymeric concentrates.

The above summary is not intended to describe each illustratedembodiment or every implementation of the subject matter hereof. Thedetailed description that follows more particularly exemplifies variousillustrative embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a scanning electron microscope image at 2000× depictingmeasurements of calcium carbonate compounds in a polymeric matrix.

FIG. 2 is a scanning electron microscope image at 1000× depictingmeasurements of talc compounds in a polymeric matrix.

DETAILED DESCRIPTION

Unless the context indicates otherwise the following terms shall havethe following meaning and shall be applicable to the singular andplural:

The terms “a,” “an,” “the,” “at least one,” and “one or more” are usedinterchangeably. Thus, for example, a liquid polymeric dispersioncontaining “a” polymer means that the liquid polymeric dispersion mayinclude “one or more” polymers.

The term “coupling agent” means an additive that improves theinterfacial adhesion between a polymeric matrix and a cellulosic filler.

The term “dispersion” means a material comprising more than one phasewhere at least one of the phases consists of finely divided phasedomains (e.g., solid particles) distributed throughout a continuousphase domain (e.g., a liquid or melt-processed solid).

The term “filler” means a solid, liquid, or gas material added to apolymer during melt processing.

The term “highly filled” means a final polymer concentrate which aftermelt processing contains greater than 80 wt % or 50 volume % of filler.

The term “liquid polymeric dispersion” means a substance that flowsfreely and comprises a polymer dispersed or dissolved in a liquidcarrier.

The term “melt processable composition” means a formulation that isprocessed, typically at elevated temperatures near or exceeding themelting point or softening point of at least one component of theformulation, by means of a polymer melt processing technique.

The term “melt processing technique” means a technique for applyingthermal and mechanical energy to melt process a polymer or composition,such as compounding, extrusion, injection molding, blow molding,rotomolding, or batch mixing. For purposes of this disclosure, meltprocessing is differentiated from thermal compression bondingapplications.

The terms “polymer” and “polymeric” mean a molecule of high relativemolecular mass, the structure of which essentially contains multiplerepetitions of units derived, actually or conceptually, from moleculesof low relative molecular mass.

The term “polymeric concentrate” means a mixture of a polymeric materialand a filler that when melt processed can be formed into a non-friablepellet or agglomerate.

The term “polymeric matrix” means a melt processable, thermoplasticpolymeric material or materials.

The terms “preferred” and “preferably” refer to embodiments that mayafford certain benefits, under certain circumstances. Other embodiments,however, may also be preferred, under the same or other circumstances.Furthermore, the recitation of one or more preferred embodiments doesnot imply that other embodiments are not useful, and is not intended toexclude other embodiments from the claimed scope.

The recitation of numerical ranges using endpoints includes all numberssubsumed within that range (e.g. 1 to 5 includes 1, 1.5, 3, 3.95, 4.2,5, etc.).

This disclosure describes highly filled polymeric concentrates that areeasier to handle, more cost effective, and more easily dispersed thancompetitive materials known in the art. In one embodiment, a filler ismelt processed with a liquid polymeric dispersion to make a polymericconcentrate. In another embodiment, the filler level after meltprocessing in the resulting polymeric concentrate is greater than 80 wt% or greater than 50 volume %. Additional embodiments may have levels inthe final concentrate greater than 90 wt % or 60 volume %. The disclosedpolymeric concentrates can be converted into articles using compounding,extrusion and molding techniques. These articles have utility in avariety of markets including automotive, building and construction,consumer and appliance markets.

A liquid polymeric dispersion may include one or more polymers that canbe delivered in liquid dispersion form. The liquid polymeric dispersionmay, for example, contain a solids content of at least about 5 wt %, atleast about 10 wt %, at least about 20 wt %, at least about 30 wt %, atleast about 40 wt %, at least about 50 wt %, or at least about 70 wt %.In one embodiment, the liquid polymeric dispersion comprises about 30-40wt % solids. In another embodiment, the liquid polymeric dispersioncomprises about 40-50 wt % solids. In another embodiment, the liquidpolymeric dispersion comprises about 50 wt % solids.

In one embodiment, the liquid dispersion is a waterborne polymericdispersion. In another embodiment, the waterborne polymeric dispersionis a waterborne polyolefin dispersion. In one embodiment, the polymer isdispersed in a liquid solvent or oil. Non-limiting examples of liquidsolvents or oils include: any organic solvents, mineral or otherhydrocarbon based oils, and silicone based oils. In another embodiment,the liquid polymeric dispersion is water-based. In another embodiment,the liquid polymeric dispersion contains a water-in-oil emulsion or anoil-in-water emulsion. In another embodiment, the liquid polymericdispersion can be made by polymerizing a polymeric precursor (e.g., asalt of hexane-1, 6-diamine and adipic acid) in a liquid carrier.

A wide variety of polymers may be provided in a liquid polymericdispersion. Non-limiting examples of polymers include high densitypolyethylene (HDPE), low density polyethylene (LDPE), linear low densitypolyethylene (LLDPE), functional polyolefin copolymers includingpolyolefin based ionomers, polypropylene (PP), polyolefin copolymers(e.g., ethylene-butene, ethylene-octene, ethylene vinyl alcohol),polystyrene, polystyrene copolymers (e.g., high impact polystyrene,acrylonitrile butadiene styrene copolymer), polyacrylates,polymethacrylates, polyesters, polyvinylchloride (PVC), fluoropolymers,polyamides, polyether imides, polyphenylene sulfides, polysulfones,polyacetals, polycarbonates, polyphenylene oxides, polyurethanes,thermoplastic elastomers (e.g., SIS, SEBS, SBS), or combinationsthereof. In some embodiments, polyolefins are well suited to serve aspolymeric matricies for the liquid polymeric dispersion. Non-limitingexamples of useful liquid polymeric dispersions include the polyolefindispersions sold under the HYPOD™ trademark by Dow Chemical or thosesold under the Michem™ or Hydrosize™ trademark by Michelman; thewaterborne sulfopolyester dispersions sold under the Eastman AQ™trademark by Eastman Chemical; or a salt of hexane-1, 6-diamine andadipic acid (AH Salt), diluted with water to form a waterborne polymericdispersion, sold by Ascend Performance.

A liquid polymeric dispersion can be melt processed with one or morepolymers. Non-limiting examples of such polymers include high densitypolyethylene (HDPE), low density polyethylene (LDPE), linear low densitypolyethylene (LLDPE), functional polyolefin copolymers includingpolyolefin based ionomers, polypropylene (PP), polyolefin copolymers(e.g., ethylene-butene, ethylene-octene, ethylene vinyl alcohol),polystyrene, polystyrene copolymers (e.g., high impact polystyrene,acrylonitrile butadiene styrene copolymer), polyacrylates,polymethacrylates, polyesters, polyvinylchloride (PVC), fluoropolymers,polyamides, polyether imides, polyphenylene sulfides, polysulfones,polyacetals, polycarbonates, polyphenylene oxides, polyurethanes,thermoplastic elastomers (e.g., SIS, SEBS, SBS), or combinationsthereof.

A liquid polymeric dispersion can be melt processed with one or morefillers. Fillers are useful in that they allow one skilled in the art toadjust physical and thermal properties of the end use article made usinga polymeric material. For example, fillers can improve physical andthermal properties of end use articles. Some fillers can also beutilized to reduce the coefficient of thermal expansion (CTE) of apolymeric article. Non-limiting examples of fillers include mineral andorganic fillers including carbonates, silicates, talc, mica,wollastonite, clay, silica, alumina, carbon fiber, carbon black, carbonnanotubes, graphite, graphene, volcanic ash, expanded volcanic ash,perlite, glass fiber, solid glass microspheres, hollow glassmicrospheres, cenospheres, ceramics, and conventional cellulosicmaterials including: wood flour, wood fibers, sawdust, wood shavings,newsprint, paper, flax, hemp, wheat straw, rice hulls, kenaf, jute,sisal, peanut shells, soy hulls, or any cellulose containing material.The amount of filler in the polymeric concentrate after melt processingis greater than 80 wt % or 50 volume %. In some embodiments, the amountof filler by volume may exceed 70% or even 80%.

In another embodiment, a liquid polymeric dispersion is melt processedwith a lightweight filler to form a lightweight highly filled polymericconcentrate. Non-limiting examples of lightweight fillers include:hollow glass microspheres, cenospheres, perlite and expanded volcanicash. Preferred lightweight fillers include hollow glass microspheres andexpanded volcanic ash. In another embodiment, a more dense filler iscombined with the lightweight filler and the liquid polymeric dispersionto form a lightweight highly filled polymeric concentrate. In anotherembodiment, a liquid polymeric dispersion is melt processed with apowdered polymer to form a highly filled polymeric system. Anon-limiting example of a preferred powdered polymer includes, but isnot limited to, polytetrafluoroethylene (PTFE).

In another embodiment, the polymeric matrix may contain other additives.Non-limiting examples of such other additives include antioxidants,light stabilizers, blowing agents, foaming additives, antiblockingagents, heat stabilizers, impact modifiers, biocides, antimicrobialadditives, compatibilizers, plasticizers, tackifiers, processing aids,lubricants, coupling agents, flame retardants, oxygen scavengers, andcolorants. The additives may be incorporated into the melt processablecomposition in the form of powders, pellets, granules, or in any otherform that can survive extrusion. The amount and type of conventionaladditives in the melt processable composition may vary depending uponthe polymeric matrix and the desired physical properties of the finishedcomposition. Based on this disclosure, those skilled in the art of meltprocessing will be capable of selecting appropriate amounts and types ofadditives to match with a specific polymeric matrix in order to achievedesired physical properties of the finished material.

Additives well suited for melt processing with the polymeric dispersionof this disclosure include coupling agents. Coupling agents can assistin the interfacial adhesion or other attraction between a filler orother additive and the polymeric matrix. Non-limiting examples ofcoupling agents include silanes, zirconates, titanates andfunctionalized polymers. Preferred coupling agents included silane andmaleic anhydride grafted polymers. Non-limiting examples of maleicanhydride grafted polymers include those sold under the trademarksPolybond™ (Addivant), Extinity™ (NWP), Integrate™ (Lyondell Basell), andFusabond™ (DuPont). Typical loading levels of coupling agents andantioxidants are approximately 0.1 to 5 wt % of the final polymericconcentrate formulation.

The highly filled polymeric concentrate composition and optionaladditives can be prepared by blending the filler and the optionaladditives into a liquid polymeric dispersion. Depending on the type andnature of polymeric matrix, this can be done using a variety of mixingprocesses that will be familiar to those skilled in the art. The liquidpolymeric dispersion and filler can be combined together by any suitableequipment available in the plastics industry, such as with a compoundingmill, a Banbury mixer, or a mixing extruder. In one embodiment, a ventedtwin screw extruder is utilized. The materials may be injected orsupplied to the extruder at various insertion points such as the throator at downstream ports in the extruder. The materials may be used in theform, for example, of a powder, a pellet, or a granular product. Themixing operation is most conveniently carried out at a temperature abovethe melting point or softening point of the polymer.

In another embodiment, the highly filled polymeric concentratecomposition and optional additives can be prepared by blending thefiller and optional additives into a liquid polymeric dispersion andprocessing directly in a pellet mill or densifier to form the highlyfilled polymeric concentrate.

The minimum temperature during melt processing is typically above thetemperature required to volatilize the liquid carrier in the dispersion.For example, if the liquid carrier is water, the temperature should begreater than 100° C. during melt processing. The volatilized liquidcarrier can be vented or pulled away (e.g., using a vacuum) from themelt processing unit. The resulting melt processed filled concentratecan be either pelletized directly into a pellet, agglomerate orgranulate form or fed from the melt processing equipment into asecondary operation to pelletize the composition (e.g., a pellet mill ordensifier) into a densified pellet, agglomerate or granulate. Thedensified pellet, agglomerate or granulate of this disclosure preferablyhas enough integrity such that it can be readily used in a subsequentcompounding, extrusion or molding step (viz., without breaking up into afine particulate during transport, conveying or feeding).

Melt-processing of the liquid polymeric dispersion and filler aretypically performed at a temperature from 800 to 300° C., although otheroptimum operating temperatures are selected depending upon the carrierboiling point(s) and the melting point, melt viscosity, and thermalstability of the polymer(s). A variety of melt processing devices, e.g.,extruders, may be used to process the melt processable compositions ofthis disclosure.

The highly filled polymeric concentrates of this disclosure have broadutility in the automotive, building and construction, consumer andappliance. Non-limiting examples of potential uses for such concentratesinclude automotive components, decking, fencing, railing, roofing,siding, containers and appliance housings.

The polymeric concentrates described herein provide significant value toplastics compounders and converters. These polymeric concentrates areeasier to handle, more cost effective and more easily dispersed thancompetitive materials currently on the market.

In the following examples, all parts and percentages are by weightunless otherwise indicated.

Examples

TABLE 1 MATERIALS Material Supplier LPD Liquid Polymeric Dispersion,HYPOD 1001, waterborne PE copolymer, 40-44 wt % solids, commerciallyavailable from Dow Chemical (Midland, MI) LPD 2 Liquid PolymericDispersion, AQ 55S, waterborne sulfopolyester, 30-33 wt % solids,commercially available from Eastman Chemical (Kingsport, TN) LPD 3Liquid Polymeric Dispersion, a salt of hexane-1, 6-diamine and adipicacid (AH Salt), diluted with water to form a waterborne dispersion at 50wt % solids, commercially available from Ascend Performance Materials(Houston, TX) PP Bapolene 4012F, 12 MFI polypropylene flake resin,commercially available from Bamberger Polymers (Jericho, NY) HDPE IneosT50-440-119 HDPE, commercially available from Bamberger Polymers Inc.,(Jericho, NY) PET PET, commercially available from Valley IndustrialNylon N66 UF NC PEL Nylon 6,6 commercially available from JedaCompounding and Distribution Services Talc 1 Silverline 303 talc,commercially available from Imerys, Inc, (San Jose, CA) Talc 2 HAR Talc,commercially available from Imerys, Inc, San Jose, CA CaCO₃ GLC 1012calcium carbonate, commercially available from Great Lakes Calcium Inc.,(Green Bay, WI) Clay Closite 15A clay, commercially available from BYKInc., (Wesel, Germany) Wood 40 mesh Maple, commercially available fromAmerican Wood Fibers, (Schoefield, WI) MS S60HS, hollow glassmicrospheres, commercially available from 3M (St. Paul, MN)

TABLE 2 EXPERIMENTAL MASTERBATCH (MB) CONCENTRATE FORMULATIONS Volume %Example LPD LPD 2 LDP 3 PP Talc 1 Talc 2 CaCO₃ Clay MS Wood Weight %Filler Filler MB1 10 90 — — — 95.8 89.3 MB2 15 85 — — — 93.5 84.0 MB3 5— 95 — — 98.0 94.4 MB4 10 — 90 — — 95.8 89.3 MB5 15 — 85 — — 93.5 84.0MB6 5 — 95 — 98.0 96.7 MB7 10 — 90 — 95.8 93.4 MB8 15 — 85 — 93.5 89.1MB9 20 — — — 80 90.9 87.0 MB10 15 40 45 50 83.3 MB11 20 60 — — 20 90.98.74 MB12 20 80 92.2 88.8 MB13 20 80 90.4 79.5

TABLE 3 EXPERIMENTAL COMPOUND FORMULATIONS AND COMPARATIVE EXAMPLES (CE)Example HDPE PET Nylon MB1 MB2 MB3 MB4 MB5 MB6 MB7 MB8 MB12 MB13 TalcCaCO₃ Clay 1 68.5 — — 31.5 — — — — — — — — — — — — 2 66.25 — — 33.75 — —— — — — — — — — — 3 69.25 — — — — 30.75 — — — — — — — — — — 4 68.5 — — —— — 31.5 — — — — — — — — — 5 66.25 — — — — — — 33.75 — — — — — — — — 669.25 — — — — — — 30.75 — — — — — — — 7 68.5 — — — — — — — 31.5 — — — —— — 8 66.25 — — — — — — — — 33.75 — — — — — 9 80 — — — — — — — — — 20 —— — — 10  — 80 — — — — — — — — 20 — — — CE1 70 — — — — — — — — — — — 30— CE2 70 — — — — — — — — — — — 30 — CE3 70 — — — — — — — — — — — — — 30

Sample Preparation

For MB1-MB9 and MB13, the filler and liquid polymeric dispersion wasblended in a plastic bag and gravimetrically fed into a 27 mm twin screwextruder (52:1 L:D, commercially available from Entek Extruders,Lebanon, Oreg.). The compounding was performed using the followingtemperature profile in zones 1-13: 100, 350, 400, 400, 400, 400, 400,400, 400, 400, 400, 400, and 400 degrees Fahrenheit (about 38, 177, 204,204, 204, 204, 204, 204, 204, 204, 204, 204, and 204 degrees Celsius,respectively). The material was run though the extruder with the dieremoved and collected as a dry particulate. The dry particulate was runthrough an electric 5″ (approximately 13 cm) pellet mill (commerciallyavailable from Pellet Masters, Chippewa Falls, Wis.) to densify thematerial. The filler masterbatches were subsequently let-down into athermoplastic matrix. For MB 10-12, the fillers and liquid polymericdispersion were blended in a plastic bag and directly pelletized in a 5″(approximately 13 cm) electric pellet mill (commercially available fromPellet Masters, Chippewa Falls, Wis.).

For the experimental compound formulations 1-8, the HDPE, MBs, talc,calcium carbonate, and clay were dry blended in a plastic bag andgravimetrically fed into a 27 mm twin screw extruder (52:1 L:D,commercially available from Entek Extruders, Lebanon, Oreg.).Comparative Examples CE1-CE3 demonstrate properties for directlycompounded mineral filled HDPE compounds. The compounding forformulations 1-8 and CE1-CE3 was performed using the followingtemperature profile in zones 1-13: 100, 350, 400, 400, 400, 400, 400,400, 400, 400, 400, 400, and 400 degrees Fahrenheit (about 38, 177, 204,204, 204, 204, 204, 204, 204, 204, 204, 204, and 204 degrees Celsius,respectively). The compounds were extruded into strands and pelletizedinto pellets approximately 1-2 mm in length. The resulting compoundswere injection molded into test specimens and characterized based onASTM D790-07 and ASTM D638-00. ASTM D790-07 provides a standardizedmethod for testing the flexural properties, such as flexural modulus andstrength, for unreinforced and reinforced plastics. ASTM D638-00provides a standardized method for testing the tensile properties ofplastics, including tensile modulus, tensile strength and elongation.Specific Gravity was determined using the Archimedes Method. Impacttesting was performed based on ASTM D256-10. The results of this testingare shown in Table 4 below.

TABLE 4 EXPERIMENTAL RESULTS Izod Flexural Flexural Specific TensileTensile Elongation Impact Modulus Strength Gravity Modulus Strength atUnnotched Example (kpsi) (kpsi) (g/cm³) (kpsi) (kpsi) Break (%)(ft-lbs/in) 1 202 4.7 1.17 289 3.2 4.9 4.22 2 197 4.7 1.17 289 3.1 4.04.20 3 199 4.4 1.17 238 2.8 5.6 5.73 4 261 4.2 1.16 233 2.8 5.8 6.18 5259 4.3 1.17 234 3.0 4.4 4.65 6 252 4.0 1.06 297 2.4 2.0 1.22 7 253 3.81.05 323 2.2 1.9 1.27 8 236 3.7 1.06 286 2.1 2.0 1.15 CE1 194 4.2 1.16241 2.9 5.1 6.25 CE2 250 4.6 1.17 282 3.3 5.0 4.35 CE3 264 4.4 1.06 3282.5 1.3 1.15

Experimental compound formulations 1-8 demonstrate the physicalproperties of the let-down compounds of this disclosure. They comparefavorably to the mechanical properties of the materials directlycompounded into virgin HPDE at the same filler loading. For example,Example 1 and CE1 have the same filler loading level, but formulation 1was processed with MB1 whereas CE1 was made by directly feeding in HDPEwith talc filler. Formulation 4 and CE2 and Formulation 7 and CE3 havethe same filler loading but with calcium carbonate and clay,respectively. These results show that the physical performance forproducts obtained by letting down the MB formulations is at least asgoof if not better than that obtained by direct feeding of the fillerwith virgin resin are roughly the same. This signifies that theadditives in the MBs may undergo improved dispersion during thelet-down, thereby enhancing the physical properties of the end compound.Ultimately, although the MB formulations have volume percentages greaterthan 50, one can still disperse the MB formulation upon let-down in afinal polymer compound.

For experimental compound formulations 9 and 10 containing MB 12 and 13,respectively, scanning electron microscopy (SEM) images were taken toexamine dispersion quality and particle size, as shown in FIGS. 1 and 2.FIG. 1 is an SEM image at 2000× of calcium carbonate compoundmeasurements 12 a, 12 b, 12 c, 12 d, 12 e, 12 f, and 12 g in 80/20 wt %PET polymeric matrix 10. FIG. 2 is an SEM image at 1000× of talccompound measurements 22 a, 22 b, 22 c, 22 d, 22 e, 22 f, 22 g, 22 h, 22i, 22 j, and 22 k in 80/20 wt % nylon 6,6 polymeric matrix 20. As shownin FIGS. 1 and 2, MB 12 and 13 can be successfully let-down in PET andnylon 6, 6, respectively. This is evident because the measured particlesize of the additives, carbonate compounds 12 in FIG. 1 and talccompounds 22 in FIG. 2, are similar to the reported size of therespective additives. Furthermore, in both FIGS. 1 and 2, the additivesalso appear evenly distributed throughout the polymer matrix,demonstrating the efficacy of the liquid polymeric dispersion.

Although specific embodiments have been illustrated and described hereinfor purposes of description of the preferred embodiments, it will beappreciated by those of ordinary skill in the art that a wide variety ofalternate or equivalent implementations calculated to achieve the samepurposes may be substituted for the specific embodiments shown anddescribed without departing from the scope of the disclosure. Thisapplication is intended to cover any adaptations or variations of thepreferred embodiments discussed herein.

What is claimed is:
 1. A highly filled polymeric concentrate comprising:one or more polymeric phases; and one or more fillers dispersedthroughout the one or more polymeric phases of the highly filledpolymeric concentrate using a liquid polymeric dispersion; wherein thehighly filled polymeric concentrate has at least 60% by volume of theone or more fillers.
 2. The highly filled polymeric concentrate of claim1, wherein the highly filled polymeric concentrate has at least 70% byvolume of the one or more fillers.
 3. The highly filled polymericconcentrate of claim 1, wherein the highly filled polymeric concentratehas at least 80% by volume of the one or more fillers.
 4. The highlyfilled polymeric concentrate of claim 1, wherein the highly filledpolymeric concentrate has at least 90% by volume of the one or morefillers.
 5. The highly filled polymeric concentrate of claim 1, furthercomprising a compatibilizer, coupling agent, or combination thereof. 6.The highly filled polymeric concentrate of claim 1, wherein the highlyfilled polymeric concentrate is produced by using a pellet mill or highspeed mixer.
 7. The highly filled polymeric concentrate of claim 1,wherein the one or more fillers includes carbon fiber, carbon nanotubes,conductive carbon, carbon black, or combination thereof.
 8. A highlyfilled polymeric concentrate comprising: one or more polymeric phases;one or more fillers dispersed throughout the one or more polymericphases of the highly filled polymeric concentrate by melt processing aliquid polymeric dispersion; wherein the highly filled polymericconcentrate has at least 80% by weight of the one or more fillers. 9.The highly filled polymeric concentrate of claim 8, wherein the highlyfilled polymeric concentrate has at least 90% by weight of the one ormore fillers.
 10. The highly filled polymeric concentrate of claim 8,wherein the highly filled polymeric concentrate has at least 93% byweight of the one or more fillers.
 11. The highly filled polymericconcentrate of claim 8, wherein the highly filled polymeric concentratehas at least 95% by weight of the one or more fillers.
 12. The highlyfilled polymeric concentrate of claim 8, further comprising acompatibilizer, coupling agent, or combination thereof.
 13. The highlyfilled polymeric concentrate of claim 8, wherein the highly filledpolymeric concentrate is produced by using a pellet mill or high speedmixer.
 14. The highly filled polymeric concentrate of claim 8, whereinthe one or more fillers includes carbon fiber, carbon nanotubes,conductive carbon, carbon black, or combination thereof.
 15. A highlyfilled polymeric concentrate comprising: one or more polymeric phases;and one or more fillers selected from a group consisting of carbonfiber, carbon nanotube, conductive carbon, and carbon black; wherein theone or more fillers are dispersed through the one or more polymericphases of the highly filled polymeric concentrate by melt processing aliquid polymeric dispersion; and wherein the highly filled polymericconcentrate has at least 50% by volume of the one or more fillers. 16.The highly filled polymeric concentrate of claim 15, wherein the highlyfilled polymeric concentrate has at least 60% by volume of the one ormore fillers.
 17. The highly filled polymeric concentrate of claim 15,wherein the highly filled polymeric concentrate has at least 70% byvolume of the one or more fillers.
 18. The highly filled polymericconcentrate of claim 15, wherein the highly filled polymeric concentratehas at least 80% by volume of the one or more fillers.
 19. The highlyfilled polymeric concentrate of claim 15, wherein the highly filledpolymeric concentrate is produced by using a pellet mill or high speedmixer.
 20. The highly filled polymeric concentrate of claim 15, furthercomprising a compatibilizer, coupling agent, or combination thereof.